Planned Maintenance (PM) (Professional Maintenance) Pillar Overview

Purpose and Philosophy of Planned Maintenance:

• Preventing Productivity Disruptions: Planned Maintenance aims to avoid disruptive breakdowns in industrial settings, emphasizing the need to preemptively address machine issues before they escalate into production halts.
• Strategic Maintenance Planning: The pillar focuses on planning and executing maintenance activities strategically to ensure optimal productivity while managing costs effectively.

Key Performance Indicators (KPIs) for Evaluation:

• Performance Metrics: KPIs such as breakdowns, short stops, and speed losses measure the effectiveness of the maintenance strategy, coupled with assessments of spare part inventory levels and mechanic efficiency.
• Work Order Handling: Efficient management of work orders and technical tickets is crucial, involving gatekeeping for prioritization and planning for effective execution.

Operational Approaches to Machine Time Losses:

• Breakdown Analysis: Detailed analysis of breakdown occurrences to identify patterns and root causes, leveraging historical data and real-time observations.
• Addressing Short Stops: Identification of recurring short stops, involving collaboration with operators for insight into solutions and clues for root cause identification.
• Managing Speed Losses: Adjusting line speeds and controlled observation to pinpoint issues causing speed reductions, allowing for proactive resolution.

Collaboration and Integration across Departments:

• Maintenance Organization Efficiency: Ensuring the maintenance apparatus can handle work orders efficiently, employing gatekeeping to prioritize tasks effectively.
• Alignment with Production Operations: Collaborating with the production department to synchronize maintenance tasks with operational schedules, avoiding wasted time due to miscommunication or unexpected production changes.

Utilization of Maintenance Performance Control System (PCS):

• Performance Evaluation: Employing a dedicated Maintenance PCS to assess the efficiency of the maintenance department, tying into the broader performance control system managed by the FI (Finance) pillar.

Evolution to Time and Condition-Based Maintenance:

• Transition to Advanced Maintenance: Advancing from reactive approaches, Planned Maintenance moves towards time and condition-based maintenance strategies.
• Expertise and Knowledge Requirements: Emphasizing the need for expertise in machinery, allowing for predictive maintenance by detecting potential failures before they impact production.

Interlinking with Other Pillars:

• Integration with Focused Improvement: Collaborating with the Focused Improvement pillar to prioritize maintenance efforts based on machine and personnel productivity assessments.
• Synergy with Autonomous Management: Aligning efforts with the Autonomous Management pillar to empower operators for autonomous inspections and operations, complementing Planned Maintenance's top-down approach.

This expanded breakdown offers a more detailed view of the Planned Maintenance pillar, covering its strategic philosophy, operational methodologies, KPI-centric evaluations, collaboration aspects, utilization of dedicated systems, evolutionary approaches to maintenance strategies, and interconnectedness with other pillars in continuous improvement frameworks.

Course Forward:

• Interested in leading a PM pillar, sub-pillar, or project team?  
• Learn more about our Machine Reliability Leader coaching program!  See the benefits below, and find more details in this link.  https://www.beltcourse.com/ci-and-pillar-leader-curricula-sp

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